101482-9091 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014829091

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101482-9091 1014829091

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Service parts 101482-9091 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101048-8150

3. GOVERNOR 105419-0440

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-2920

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4910

11. Nozzle and Holder 16600-54T01

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3390

14. NOZZLE

105017-0900

15. NOZZLE SET

Include in #1:

101482-9091 as INJECTION-PUMP ASSEMBLY

101491-0200 as _

Cross reference number

ZEXEL 101482-9091 1014829091

Zexel num

Bosch num

Firm num

Name

101482-9091

INJECTION-PUMP ASSEMBLY
14BC PE4A,5A, PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 44.4 43.4 45.4

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8 6 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62 62 72

Max. variation between cylinders % 0 -10 10

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting (5)Rack difference between N = N1 and N = N2
----------
K=14 N1=1100r/min N2=800r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=18deg+-5deg b=11deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=12deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(100deg)

Information:

1. Disassembly and Assembly of General Parts
1.1 Oil SealsWhen driving oil seals into place, respect the following instructions. Driving Seals into Housing:(a) Orient the seal lip correctly, making sure it is not damaged.(b) Before driving a seal into place, apply a light coat of grease to the periphery of the seal that fits into the housing.(c) Use a driving tool like the one shown in the drawing that is specially designed for the purpose. The tool can properly guide the lip and hold evenly the top of the seal when it is tapped, so it allows the seal to be driven straight down. Do not use hammers on bare seals as seal will be damaged and consequently oil leak will result.
Oil seal driving tool Driving Seals onto Shaft:(a) Coat the seal lip with grease.(b) Use a seal guide like the one shown in the drawing when the shaft has steps, splines, threads or keyways.
Oil seal guide1.2 O-RingsUse a guide when it is necessary to move O-rings over steps, splines, threads or keyways to install them. Apply a light coat of grease to O-rings before fitting them.
O-ring guide1.3 Bearings(1) When driving bearings into place, be sure to tap the race that is being fitted. (If the inner race is being fitted, tap the inner race. Likewise, if it is the outer race that is being fitted, tap the outer race.) Use fitting tools like the one shown in the drawing that are appropriate for inner or outer races.
Bearing fitting tool(2) Bearings are best fitted using a press as shock loads and errors can be minimized.
Fitting bearing using a press1.4 Lock PlatesAlways bend lock plates properly. The drawing on the right shows some of typical lock plates being bent properly and improperly.1.5 Split Pins and Spring PinsAs a rule, all split pins must be replaced with new ones after each removal. It is also important to bend split pins properly. Spring pins must be driven into place completely.
Typical locking plates with good and bad bends